Miniature multiple conductor electrical connector

ABSTRACT

Two electronic components having fine pitch arrays of terminals can be disconnectably interconnected by a multiple electrical connector that includes a pair of intermeshable members. Each of those members has an electrically insulative body with a structured surface including a plurality of tapered elements. Tapered sides of those elements fit flush against each other when the two members intermesh, and the members become strongly adhered to each other when the tangent of the half angle of said tapered sides is no greater than the coefficient of friction of the material of the contacting surfaces. Each of the members has a plurality of electrically conductive segments in position to make good electrical contact when the members intermesh.

This is a continuation of application Ser. No. 07/510,573 filed Apr. 18,1990, now U.S. Pat. No. 5,071,363.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention concerns multiple conductor electrical connectors that canbe used for electrically interconnecting two electronic components thathave large numbers of electrical terminals. The invention isparticularly concerned with multiple conductor electrical connectors bywhich large arrays of closely spaced terminals can be interconnected,e.g., microchips and microchip interconnects.

2. Description of the Related Art

In order to electrically interconnect two arrays of electricalterminals, each terminal of one array can be connected to one of aplurality of pins, each of which fits into a spring-loaded socket thatis connected to a terminal of the other array. When the terminals have a"fine pitch," i.e., are closely spaced, as are those of microchips andmicrochip interconnects, pin-and-socket connectors tend to be expensiveand difficult to manufacture.

European Pat. Publication No. 0,223,464 published May 27, 1987 (Reyleket al.) is concerned with multiple conductor electrical connectors forfine pitch electronic components, e.g. 0.1 mm between the centers ofadjacent terminals. The EPO patent publication describes two priortechniques for electrically interconnecting facing terminal arrays oftwo electronic components. One technique utilizes "flip chip" devices,and another utilizes a layer of polymer containing electricallyconductive particles that deform when the two components are pressedagainst the polymeric layer so that each deformed particle provides anelectrical path between opposed terminals. When the polymer is anadhesive, it can bond the two components together. When the polymer isnot an adhesive, a clamp is used to maintain the electrical connectionsand must be so designed and used that sufficient pressure is applied toensure good electrical contact at every connection. Whether or not thepolymer is an adhesive, it should electrically insulate adjacentparticles from each other.

Like the particle-containing polymeric layer produced by the secondtechnique, the connector of the Reylek EPO publication has a polymericlayer containing electrically conductive elements except that in theReylek connector, each of the elements is a coating of electricallyconductive material and the elements can be uniformly spaced. A Reylekconnector can be made by forming a pattern in a rigid plastic sheet,depositing a metal layer over the pattern, covering the metal layer witha polymeric matrix, removing the plastic sheet, covering thethus-exposed side of the metal layer with a polymeric matrix, and thengrinding off polymer at both sides until segments of the metal layerextend only between two flat faces of the polymeric matrix. The metalsegments can have a variety of shapes, e.g., flat rectangles, cylinders,cones, pyramids, hemispheres, squares, and cubes that can be open on oneor both ends. When the polymeric matrix is an adhesive, it can bond thetwo electronic components together, but this prevents the componentsfrom being disconnected and reconnected.

U.S. Pat. No. 4,875,259 (Appeldorn), which does not mention electricalconnectors, provides intermeshable members that can be used in pairs asmechanical fasteners. Each of the members has a structured surfaceincluding a plurality of tapered elements, each element having at leastone side inclined relative to a common plane at an angle sufficient toform a taper. Upon being intermeshed with the tapered sides of the twoelements in contact, the pair of members become frictionally interlockedwhen the tangent of the half angle of the tapered sides is no greaterthan the coefficient of friction of the material of the contactingsurfaces. Individual tapered elements can be exceedingly small.

The disclosure in the Appeldorn patent is incorporated herein byreference.

SUMMARY OF THE INVENTION

The invention provides multiple conductor electrical connectors that canelectrically interconnect two electronic components having fine pitcharrays of terminals. Other than pin-and-socket electrical connectors,those of the invention are believed to be the first that can beconnected and reconnected without using a clamp.

A multiple conductor electrical connector of the invention includes apair of intermeshable articles which, like those of the Appeldornpatent, comprise:

a first member having at least one major surface and at least a portionof said major surface being a structured surface;

a second member having at least one major surface and at least a portionof said major surface being a structured surface; and

said structured surfaces of said first member and said second membereach including a plurality of solid tapered elements, each elementhaving at least one side inclined relative to a common plane in each ofsaid members at an angle sufficient to form a taper so that said elementof said first member may mesh with said elements of said second memberwhen brought into contact with one another and said first member mayadhere to said second member at least partially because of thefrictional force of adherence of said contacting sides of said elementso said first member and said elements of said second member and whereinthe tangent of the half angle of the tapered sides of the element is nogreater than the coefficient of friction of the material of thecontacting surfaces.

The multiple conductor electrical connector of the invention differsfrom Appeldorn's intermeshable articles in that:

each of said members has an electrically insulative body; and

an electrically conductive segment is at a surface of at least one ofsaid contacting sides of an element of one member in position to contactan electrically conductive segment of the other member when the membersintermesh.

For most uses, there is an electrically conductive lead at each of saidelectrically conductive segments, and some of the leads can be utilizedto carry off heat such as may be generated by electricity flowingthrough the electrical connector and electronic components which itinterconnects. For the same purpose, one or both of the intermeshablemembers can carry heat conductors, each of which is connected to a heatsink, and they need not be electrically conductive.

The novel multiple conductor electrical connector is primarily usefulwhen it is miniature in size for electrically interconnecting arrays ofclosely spaced terminals. For most uses, each of its pair ofintermeshable members will have at least 10 and as many as 500 or moretapered elements at the same density as the terminals of the electroniccomponents to be interconnected. For example, there may be from 0.5 to20 conductive segments per mm. and their height may be from 0.1 to 10 mmto accommodate multiple terminals now on the market.

By making both members of the novel connector identical, inventory issimplified. While intermeshable members consist of male tapered elementson one member of a novel connector and female tapered elements on theother. For example, see FIGS. 11, 21, 23, 24 and 25 of the drawing. Wheneach member of a novel connector has both male and female taperedelements, the members can be identical.

The electrically insulative body of each intermeshable member of thenovel connector preferably is formed by replicating the surface of areusable master, which surface is the negative of the tapered elementsthat are to be formed. For high speed replication, the electricallyinsulative material of the body of the novel connector is athermoplastic resin that can be cast, extruded or injected onto, orotherwise formed on, the surface of the master which preferably is heatconductive to provide quick solidification, cooling, and reuse. Apreferred material for the master is stainless steel.

A number of commercially available thermoplastic resins can preciselyand stably replicate the surface of a master and so are useful formaking the electrically insulative bodies of the novel connector. Theresulting electrically insulative bodies should be resistant totemperatures and other conditions to be encountered in use, and theselection of material for the bodies should take into account thedesirability of avoiding any need to change or otherwise renew themaster until thousands of the intermeshable members have been formed.Preferred thermoplastic resins for the electrically insulative bodiesinclude commercially available polyesters such as poly(ethyleneterephthalate) and liquid crystal polymers. Other useful thermoplasticresins include acrylics, vinyls, polyethylenes and polycarbonates, allof which are readily available at reasonable cost. Other usefulmaterials that are electrically insulative and can precisely replicate amaster include other polymeric materials, ceramics, and glasses.

After forming the electrically insulative body of an intermeshablemember, surfaces of its tapered elements can be provided withelectrically conductive segments by the sequential steps of:

(a) depositing a thin film of electrically conductive metal, e.g., byvapor deposition,

(b) electroplating a thicker layer of the same or a differentelectrically conductive metal, and

(c) removing portions of the metal to separate it into segments that areelectrically insulated from each other.

Those electrically conductive metal segments can substantiallycompletely cover every tapered side of every element or only selectedportions thereof. Some or all of the tapered sides can be completelyuncovered. Because some polymeric materials have substantially highercoefficients of friction in contact with each other than do inexpensiveelectrically conductive materials, a significant proportion of eachtapered side of some elements can be left uncovered by the electricallyconductive material, hence providing greater leeway in designing thenovel connector. For example, each intermeshable member of a multipleconductor electrical connector of the invention can have first andsecond tapered sides and electrically conductive segments covering onlythe first tapered sides.

Each intermeshable member of a novel electrical connector can be apolymeric material which has such a high coefficient of friction incontact with itself that uncovered tapered sides can adhere so stronglythat the connector cannot be disconnected at room temperature withoutdamage but can be disconnected when cooled to a temperature that doesnot damage the connector. A polymer that has relatively high Tg, e.g.,from 40° to 80° C, and is nontacky at room temperatures can have anexceedingly high coefficient of friction in contact with itself.

Copper is useful for the electrically conductive segments of the novelconnector, it being low in cost and highly electrically conductive.Where cost is of less importance, silver and gold are more preferred.Gold segments can be readily formed to have exceedingly smooth surfaces.When smooth, gold has a very high coefficient of friction in contactwith itself.

Although the electrically conductive segments of the novel connector canbe quite thin compared to the electrically insulative bodies, for someuses they should be relatively thick, e.g., where the electric currentis relatively high. Higher electric current can also be accommodated byleaving several adjacent segments interconnected, or a portion of eachmember of the novel electrical connector can be formed entirely ofelectrically conductive material. Such a wholly conductive area can alsoor, alternatively instead be utilized in a heat sink.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be more fully described with reference to theaccompanying drawings, all figures of which are schematic. In thedrawings:

FIGS. 1 and 2 are perspective views illustrating stages of a method formaking one intermeshable member of a first multiple conductor electricalconnector of the invention;

FIG. 3 is a cross sectional view through a pair of said first multipleconductor electrical connectors;

FIG. 4 is a perspective view of one member of a second multipleconductor electrical connector of the invention;

FIG. 5 is a cross sectional view through one member of a third multipleconductor electrical connector of the invention;

FIG$. 6 and 7 are cross sectional views through one member of each offourth and fifth multiple conductor electrical connectors of theinvention;

FIGS. 8 and 10 are top views of one member of each of sixth and seventhmultiple conductor electrical connectors of the invention;

FIG. 9 is a cross sectional view through apparatus useful for making amember which is similar in appearance to that shown in FIG. 8;

FIG. 11 is a fish-eye view of an eighth multiple conductor electricalconnector of the invention, one member of which has a plurality oftapered elements similar to those of the member shown in FIG. 8;

FIGS. 12-14 are perspective views illustrating stages of a method formaking a ninth multiple conductor electrical connector of the invention;

FIG. 15 is a cross sectional view through a tenth multiple conductorelectrical connector of the invention;

FIG. 16 is a perspective view showing the use of said ninth multipleconductor electrical connector to interconnect two flexible circuits orflat ribbon cables;

FIG. 17 is a perspective view showing the use of said ninth multipleconductor electrical connector to interconnect two printed circuitboards;

FIG. 18 is a cross sectional view through an eleventh multiple conductorelectrical connector of the invention;

FIG. 19 is a perspective view of one member of a twelfth multipleconductor electrical connector of the invention that has been connectedto a printed circuit board.

FIG. 20 is a perspective view of a thirteenth multiple conductorelectrical connector of the invention;

FIG. 21 is a fish-eye view of a fourteenth multiple conductor electricalconnector of the invention;

FIG. 22 is cross sectional view through a fifteenth multiple conductorelectrical connector of the invention;

FIG. 23 is a perspective view of a sixteenth multiple conductorelectrical connector of the invention;

FIG. 24A is a perspective view of a seventeenth multiple conductorelectrical connector of the invention;

FIG. 24B is a magnified partial view of one of the elements of FIG. 24A;

FIG. 25 is a perspective view of an eighteenth multiple conductorelectrical connector of the invention; and

FIG. 26 is a perspective view of a nineteenth multiple conductorelectrical connector of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

In FIG. 1, a major surface of a stainless steel master 10 is firstformed to have a plurality of spines 11 and furrows 12. Over the spinesand furrows is formed a thin layer 15 of electrically conductive metal.FIG. 2 shows that after removing the metal from the apices 16 of thespines 11, a relatively thick layer of a polymeric, electricallyinsulative material 17 is formed over the metal and exposed apices. Themaster 10 is then removed, and the metal is removed at the crown 18 ofeach ridge 26 of the resulting intermeshable member 22. That and anidentical member can be intermeshed to provide a multiple conductorelectrical connector 24 shown in FIG. 3. Each intermeshable member 22has an electrically insulative body 23, and along its major surface is astructured surface including a plurality of tapered elements (ridges26), each having two identically tapered sides, each of which is coveredwith a metal segment 15A or 15B of the electrically conductive metallayer 15. As intermeshed, the metal-covered tapered sides fit flushagainst each other in good electrical contact. For the two intermeshingmembers 22 to adhere to one another, the tangent of the half angle oftheir tapered sides should be no greater than the coefficient offriction of the contacting electrically conductive metal segments.

As is illustrated in FIG. 3, each element 26 is sized such that when theelements are brought into contact with one another to mesh, they willcontact each other only along the sides of elements, leaving a cavity 28beyond the crown 18 of each element, thus ensuring side contact.However, there need be no cavity as long as the forces of contact at thecrowns is no greater than the frictional forces associated with thesides.

The thickness of the intermeshable members 22 depends upon theparticular application. Thus, the member 22, for some applications, maybe formed of a thin, flexible sheet or film which can be flexed to allowseparation and repositioning.

In FIG. 4, one intermeshable member 32 of a second multiple conductorelectrical connector has an electrically insulative body 33 formed tohave a plurality of tapered elements (ridges) 36, each having twoidentically tapered sides. Each side is covered with at least threemetal segments 35A', 35A", 35A"' and 35B', 35B", 35B"', each of which isinset into the tapered side so that the metal and insulative surfaces ofthe tapered side lie in a plane. Both of the metal-to-metal contacts andthe insulative-to-insulative contacts contribute frictional force to theinterlocking of the intermeshable members. The metal segments areinsulated from each other except being interconnected across each groovebetween adjacent elements 36. At each such interconnection is a metalpin 37', 37" that protrudes beyond the under surface 38 of theinsulative body 33. When the member 32 and a second corresponding memberare intermeshed, current can flow through each pin 37' to both adjacentmetal segments 35A' and 35B', to a pair of corresponding metal segmentson a second intermeshing member (not shown), and to the pin at thegroove between those metal segments of the corresponding member.

In FIG. 5, one intermeshable member 42 of a third multiple conductorelectrical connector has an electrically insulative body 43 formed tohave a plurality of tapered elements (ridges) 46, each having twoidentically tapered sides, one covered with a metal segment 45 and theother uncovered. The underside of the electrically insulative body 43 isformed with stress-relief recesses 47. The crown of each element has achamfer 49 to facilitate alignment. When the member 42 and an identicalmember intermesh, their metal-covered tapered sides fit flush againsteach other in good electrical contact. For the two members to adhere toone another, the tangent of the half angle β of their tapered sidesshould be no greater than the coefficient of friction of theelectrically conductive metal in contact with itself.

In FIG. 6, one intermeshable member 52 of a fourth multiple conductorelectrical connector has an electrically insulative body 53 formed tohave a plurality of tapered elements (ridges) 56, each having onetapered side which is covered with a metal segment 55A. The half angle βof the tapered side is indicated in FIG. 6. The other side 56B isuncovered, and its half angle is zero. When two members 52 intermesh,both their metal segments 55A and their uncovered sides 56B fit flushagainst each other.

In FIG. 7, one intermeshable member 62 of a fifth multiple conductorelectrical connector has an electrically insulative body 63 formed tohave a plurality of tapered elements (ridges) 66, each having twoidentically tapered sides formed with longitudinal recesses 67A and 67B.Covering each tapered side and the wall of each recess is a metalsegment 65A or 65B. Fitting into each metal-covered recess 67A and 67Bis an electrically conductive wire 69A and 69B, respectively, whichwires extend longitudinally beyond the member 62 to act as leads.

In FIG. 8, one intermeshable member 72 of a sixth multiple conductorelectrical connector has an electrically insulative body 73 formed tohave a plurality of tapered elements 76, each in the form of a truncatedpyramid having four tapered sides, two of which are covered with metalsegments 75A and 75B.

FIG. 9 shows a master metal mold 80 that has a plurality of opencavities 81, the walls of which form truncated pyramids. Covering thecavities is a polymeric substrate (film) 83 that has good heatresistance such as a polyimide. At each of the cavities 81, thepolymeric film is formed with a passage 87 through which a low-meltingelectrically conductive metal can be injected to fill the cavities,after which the polymeric film 83 can be stripped from the mold,carrying with it an array of solid metallic truncated pyramids. In theresulting intermeshable member, the polymeric film 83 forms anelectrically insulative body, the solid metallic truncated pyramids areelectrically conductive segments, and the column of metal filling each fthe passages 87 can serve as a lead. At the exposed surface of thepolymeric film, the passages 87 are formed with counterbores 89 toprovide a bead on the end of the metal column to lock the polymeric filmto the intermeshable member. To bleed off air, the mold 80 can have atiny channel 88 leading from each cavity to the opposite surface.

In FIG. 10, one intermeshable member 92 of a seventh multiple conductorelectrical connector has an electrically insulative body 93 formed tohave a plurality of tapered elements 96, each having six tapered sides.One or more of those tapered sides can be covered with metal segments,or the elements can be solid metal segments.

In FIG. 11, the electrically insulative body 103 of an intermeshablemember 102 is adhered to a microchip 100, such as devices that aresometimes referred to as "gate arrays", by an adhesive layer 101 that isfilled with laterally spaced, soft silver particles. Formed on theexposed surface of the insulative body 103 are a plurality ofelectrically conductive elements 106 in the form of truncated pyramids.From the base of each truncated pyramid, a column of electricallyconductive metal (not shown) extends to the hidden surface of theinsulative body and is electrically connected to pads (not shown) of theunderside of the microchip 100 by the silver particles in the adhesivelayer 101. Each of the elements 106 can intermesh with metal segments105 lining pyramidal openings 106A in a printed circuit board 103A toprovide an eighth multiple conductor electrical connector 104 of theinvention. In yet another embodiment, the pyramidal elements 106 can besolid metal formed directly on the microchip by laying against thesurface of the microchip 100 a heat-resistant film that has been formedwith cavities, each in the shape of a truncated pyramid. The film isstripped away after filling the cavities with metal.

FIG. 12 shows a stainless steel master 110 and a piece of electricallyconductive metal sheet 115 in position to be forced, as shown in FIG.13, into a furrow 111 of the master by a tool 111A. After so inserting ametal piece into each furrow, a relatively thick layer of a polymeric,electrically insulative material 113 is formed over the metal, as shownin FIG. 14, leaving protruding electrically conductive leads 115A. Afterremoving the master 110, metal is removed from the crown of each element(ridge) 116 of the resulting intermeshable member 112 which, with anidentical member, provides a ninth multiple conductor electricalconnector 114 shown in use in FIGS. 16 and 17.

In FIG. 15, one intermeshable member 122 of a tenth multiple conductorelectrical connector has an electrically insulative body 123 formed tohave a plurality of tapered elements (ridges) 126, each having twotapered sides. Press fit into bores at each groove between adjacentridges are electrically conductive pins 128. An electrically conductivemetal layer 125 has been applied across the tapered sides and groovesand then cut away at 129 on one side of each pin so that each pin iselectrically connected to only one set of metal segments 125A. Hiddenbehind each of the electrically conductive pins 128 is another pin wherethe metal layer is cut away to connect the hidden pins to the othermetal segments 125B.

The intermeshable member 122 of FIG. 15 incorporates two means forpreventing misalignment. First, the grooves between adjacent ridges 126have differing depths. Second, the grooves are of differing widths, andthe larger crowns 126A of the ridges are too wide to fit into thenarrower grooves. A third alignment means (not shown) can be provided byforming each of the intermeshable members with a relatively large pin orridge and mating socket or groove at each end of the tapered elements.Such relatively large ridge-groove elements preferably have taperedsides, the tangent of the half angle of which is no greater than thecoefficient of friction of the materials of their contacting surfaces.

In FIG. 16, two intermeshable members 112, made as shown in FIGS. 12-14,are in position to be used to interconnect disconnectably two flexiblecircuits or ribbon cables 130 and 131. Each conductor of each flexiblecircuit or ribbon cable terminates at an electrically conductive socket137 that receives one of the leads 115A of a member 112.

In FIG. 17, two intermeshable members 112, made as shown in FIGS. 12-14,are intermeshed to interconnect disconnectably two printed circuitboards 140 and 141. Each of the leads 115A is soldered to a pad 147 ofone of the printed circuit boards.

In FIG. 18, two identical intermeshable members 142 form an eleventhmultiple conductor electrical connector 144. Each member 142 has anelectrically insulative body 143 formed to have a plurality of taperedelements (ridges) 146, on each wall of which are four tapered sides.Covering each of the tapered sides is a thin metal segment 145A-D on onewall and 145E-H on the other. Metal segments of each member fit flushagainst corresponding metal segments on the other, and leads (not shown)extend longitudinally from each member to opposite ends of theconnector.

In FIG. 19, one intermeshable member 152 of a twelfth multiple conductorelectrical connector of the invention has an electrically insulativebody 153 formed to have a plurality of tapered ridges 156, each havingtwo identically tapered sides. Covering each tapered side is a metalsegment 155A or 155B, each of which extends across the front face of themember to its undersurface. Each extension of the metal segments 155Aand 155B is soldered to a pad 158 of a printed circuit board 159. Inorder to make the intermeshable member 152, the front face of theinsulative body 153 has been formed with recesses in the areas of theextensions of the metal segments 155A and 155B. Then after applyingmetal to the entire surface of the insulative body 153 except itsundersurface, its surface has been abraded to remove metal at the crownof each ridge 156 and between each of the metal segments 155A and 155B.

In FIG. 20, a first intermeshable member 162 has an electricallyinsulative body 163 that is formed with a plurality of elements (ridges)166. The identically tapered sides of the ridges have been recessed inpart so that when covered with metal, a portion 165A of each metalsegment is recessed with respect to another portion 165C. Electricallyconnected to each of the recessed portions is an electrically conductiveknife edge 168A or 168B. Intermeshable with the first member 162 is asecond member 172 which has an electrically insulative body 173 that isformed with a plurality of elements (ridges) 176. Each identicallytapered side of each of the ridges 176 is covered with a metal segment175A or 175B except at a longitudinal recess 178. Fitting into eachrecess is an insulated electrically conductive wire 178A or 178B, whichwires extend longitudinally beyond the member 172 to act as leads. Whenthe two members 162 and 172 intermesh, the knife edges 168A and 168B cutthrough the insulation of each of the wires 178A and 178B, respectively,thus electrically interconnecting the electrically conductive core ofeach wire to both of the adjacent metal segments, e.g., the core of thewire 178B through a knife 168A to the metal segment 165 A & C, and fromthere to the metal segment 175A. The two members 162 and 172 adhere toone another when the tangent of the half angle of their tapered sides isno greater than the coefficient of friction of the metal where theportion 165C fits flush against the metal segment 175A.

In FIG. 21, a first intermeshable member 182 of a multiple conductorelectrical connector 184 has an electrically insulative body 183 whichis formed with annular elements (grooves), the identically tapered sidesof which are faced with electrically conductive segments 185. The secondintermeshable member 182A has an electrically insulative body 183A whichis formed with annular elements (ridges) 186A, the identically taperedsides of which are faced with electrically conductive segments 185A. Anelectrically conductive wire 187 is soldered to each of the electricallyconductive segments 85 of the first member 182, and an electricallyconductive wire 187A is soldered to each of the electrically conductivesegments 185A of the second member 182A. When intermeshed, themetal-covered tapered sides of the ridges and grooves fit flush againsteach other in good electrical contact and are well adhered because thetangent of the half angle of their tapered sides is no greater than thecoefficient of friction of the electrically conductive segments 185 and185A in contact with each other.

In FIG. 22, identical intermeshable members 192A and 192B of a fifteenthmultiple conductor electrical connector 194 intermesh except beingseparated at the identically tapered sides of their elements (ridges)196 by a matrix of material, such as a layer 197 of uniform thicknessthat has been adhered to and covers the structured surface of the uppermember 192A. The polymeric layer 197 is filled with laterally spaced,soft silver particles 198 which electrically interconnect metal segments195A and 195B that cover the tapered sides of each of the ridges 196.Instead of soft particles, the adhesive can be filled with hard metalspheres when the metal segments 195A and 195B are relatively soft. See,for example, EPO Pat. Publ. No. 03330452 published 30 Aug., 1989(Calhoun); the contents of which are incorporated herein by reference.The half angle of the tapered sides of the ridges 196 is no greater thanthe coefficient of friction between the polymeric layer 197 and themetal segments 195A and 195B covering the tapered sides of the member192B. Preferably, the polymeric layer 197 is nontacky to permit the twomembers 192A and 192B to be disconnected and reconnected.

In FIG. 23, a first intermeshable member 202 has an electricallyinsulative body 203 that is formed with a plurality of elements (ridges)206, one of which is shown. Intermeshed with the first member 202 is asecond member 212 which has an electrically insulative body 213 that isformed with a plurality of elements (ridges) 216, parts of two of whichare shown. Each of the ridges 206 and 216 has identical dual-taperedsides. The steeply tapered sides 206A and 216A are uncovered, and theirhalf angle is no greater than the coefficient of friction of thematerial of the electrically insulative bodies 203 and 213 in contactwith each other. Each shallow tapered side of each ridge 216 is partlycovered by a metal segment 215 that extends across a V-groove 217.

When the members 202 and 212 are intermeshed as shown with a soft metalwire 208 resting in the V-groove 217, the crown of each ridge 206 of thefirst member 202 presses and slightly deforms the wires into goodelectrical contact with the metal segments 215, thus electricallyinterconnecting the wire to a metal segment 215, while the steeplytapered sides 206A and 216A fit flush against each other to frictionallyinterlock the two members 202 and 212.

To better ensure engagement between the tapered sides 206A and 216A, thecrown of each ridge 206 can be covered with a relatively soft,compressible material.

In FIG. 24A, an edge of a printed circuit board 222 has been formed atboth faces with a plurality of elements (flutes) 226, each elementhaving two tapered sides, each tapered side being covered with a metalsegment 225 (as shown in greater detail in FIG. 24B) which in turn iselectrically connected to a lead 227 on a face of the printed circuitboard 222. The edge of the printed circuit board fits into a hollowmember 222A that has an electrically insulative body. The interior sidewalls of the hollow member 222A are formed with grooves having taperedsides, each covered with a metal segment 225A that is electricallyconnected to a metal pin 227A. When the edge of the printed circuitboard is lowered into the hollow member 222A, their metal segments 225and 225A, respectively, fit flush against each other to afford bothfrictional interlocking and electrical interconnection.

The multiple conductor electrical connector 234 shown in FIG. 25 couldbe similar in construction to that of FIG. 24, but instead of having ametal segment on each side of each flute of its male member 232, thebroad face of each flute is covered with a metal segment 235. Solderedto each metal segment 235 is an electrically conductive metal pin 237.Covering the broad face of each groove of the female member 232A of theelectrical connector 234 is a metal segment 235A that is electricallyconnected (means not shown) to a lead 237A on a printed circuit board238A.

The multiple conductor electrical connector 244 of FIG. 26 has threeidentical members 242, each having an electrically insulative body 243with a structured surface at two major surfaces. Each of the structuredsurfaces is formed to have a plurality of tapered elements (ridges) 246,the identically tapered sides of which are covered with metal segments245. Each of the members 242 is formed with bores 247 to receive metalpins (not shown) by which metal segments at one major face of eachmember can be electrically connected to metal segments at the otherface. When the members 242 are brought together with their ridges 246intermeshed, they become frictionally interlocked by the contactingmetal segments 245 which thus become electrically interconnected. Theaforementioned metal pins do not interfere with the frictionalinterlocking when they are short enough not to protrude further than thethickness of the cavity between the interlocking ridges and grooves. Tothe extent that the pins might interfere, the members can be offsetduring intermeshing.

EXAMPLE 1

A multiple conductor electrical connector was made to be similar inappearance to that of FIG. 14 The electrical insulating body 113 wasglass filled polysulfone. Thirty-three 0.4-mm holes were drilled toreceive pins 115A. One surface was then machined to create ridges 1161.8-mm high on 1.25-mm centers, the tapered sides of which had ahalf-angle β of 3°, with each of the tapered sides centered on one ofthe 0.4-mm holes After inserting a phosphor bronze pin into each hole,the structured surface was electrolessly plated with copper and thenelectroplated with additional copper to a total thickness of about 30μm. Then the copper at the crowns of the ridges was abraded away, andthe copper at the grooves was removed using a diamond saw.

Two of the resulting members were intermeshed in areas not occupied bypins and with an overlap of about 6 mm. Doing so created thirty-twoelectrical connections having resistances ranging from 19 to 250 mΩ. Thetwo members were so interlocked that they would not separate with one'sfingertips except by a progressive disengagement, i.e., by pulling themapart at one end of the electrical connector that was bordered by one ofthe ridges.

EXAMPLE 2

A multiple connector was made by embossing a polyethylene film underheat and pressure against a metal master having a nickel surface, thusaffording to the polyethylene a structured surface like that of FIG. 3.The ridges were 0.37-mm high, on 0.25-mm centers, and their taperedsides had a half-angle β of 3°. Using a mask, copper was vapor depositedonto the structured surface to a thickness of about 0.2 μm in stripescovering 6 or 7 adjacent ridges separated by about 3 unmetallizedridges. The metallized film as cut into two members.

These were intermeshed with an overlap of about 10 mm and with 20 pairsof metallized stripes aligned. The interconnection resistance betweentwo points 2.54 cm apart including the 10 mm overlap of each contactingpair of stripes was from 20 to 30 ohms. The two members were interlockedsuch that to separate them with one's fingertips, it was necessary topull them apart at one end of the electrical connector.

What is claimed is:
 1. A multiple conductor electrical connectorcomprising: first and second members, each having a connecting meansprovided on a major surface thereof for engagement with one another soas to physically fasten said first and second members together, saidconnecting means for each member comprising a structured surfaceincluding a plurality of tapered elements, said tapered elements eachhaving a tapered side inclined relative to a common plane in each ofsaid members so that when the connecting means of said members areengaged with one another said tapered elements of said first memberintermesh with tapered elements of said second member while contactsurfaces of said tapered sides of said tapered elements are engaged withone another without interlocking of said tapered elements, said firstand second members each comprising an electrically insulative body and aplurality of electrically conductive segments, wherein an electricallyconductive segment is provided as the contact surface of a plurality ofsaid tapered sides of said tapered elements of each of said members withan electrically conductive segment on one of said tapered sides of onemember insulated from an electrically conductive segment of another ofsaid tapered sides of the same member so that electrically conductivesegments of said first member engage with electrically conductivesegments of said second member when said first and second members arefastened together to provide a plurality of electrical connections, andthe engagement between electrically conductive segments at eachelectrical connection also provides the only physical fastening that isneeded in order to provide each electrical connection with a sufficientforce to ensure such electrical connection.
 2. A multiple conductorelectrical connector as defined in claim 1 wherein said tapered side ofsome of said plurality of tapered elements is free from saidelectrically conductive segments.
 3. A multiple conductor electricalconnector as defined in claim 1 wherein at least some elements on onemember are pyramidal projections and elements, and the elements on othermember which contact said pyramidal projections when the two membersintermesh are pyramidal depressions.
 4. A multiple conductor electricalconnector as defined in claim 1 wherein a polymeric layer of uniformthickness that is filled with laterally spaced, electrically conductiveparticles is adhered to and covers the structured surface of one of saidmembers.
 5. A multiple conductor electrical connector as defined inclaim 1 wherein a plurality of said electrically conductive segments areon said one tapered side of each of a plurality of said elements andspaced from each other, and each conductive segment of one membercontacts a conductive segment of the other member when the membersintermesh.
 6. A multiple conductor electrical connector as defined inclaim 1 and further comprising an electrically conductive lead at eachof said electrically conductive segments.
 7. The multiple conductorelectrical connector of claim 1, wherein the tangent of the half angleof said tapered sides is no greater than the coefficient of friction ofthe material of the contact surfaces thereof.
 8. A multiple conductorelectrical connector as defined in claim 1 wherein each element has asecond side inclined relative to a common plane at an angle sufficientto form a tape that fits flush against a tapered side of an element ofthe other member when the members intermesh.
 9. A multiple conductorelectrical connector as defined in claim 8 wherein there is anelectrically conductive segment covering only a portion of each of aplurality of said tapered sides.
 10. A multiple conductor electricalconnector as defined in claim 8 wherein at least one of saidelectrically conductive segments is on each of said first-mentionedtapered sides while each second tapered side is substantially free fromsaid electrically conductive segments.
 11. A multiple conductorelectrical connector as defined in claim 1 wherein said elements formridges and grooves, and the ridges of each member fit into the groovesof the other member when the members intermesh.
 12. A multiple conductorelectrical connector as defined in claim 11 wherein said ridges andgrooves are annular.
 13. A multiple conductor electrical connector asdefined in claim 11 wherein said ridges and grooves are linear.
 14. Themultiple conductor electrical connector of claim 11, wherein at leastone of said ridges is provided with a plurality of tapered sides andeach of said plurality of tapered sides is provided with an electricallyconductive segment that are insulated from one another.
 15. A multipleconductor electrical connector as defined in claim 11 wherein saidelements on one member form flutes, each having two tapered sides thatfit flush against tapered sides of grooves on the other member when thetwo members intermesh.
 16. A multiple conductor electrical connector asdefine din claim 15 wherein the member becoming fluted is a printedcircuit board, and the flutes are formed in both faces of the printedcircuit board.
 17. A multiple conductor electrical connector as definedin claim 1 wherein electrically conductive segments on one of saidmembers are narrow.
 18. A multiple conductor electrical connector asdefined in claim 17 wherein electrically conductive segments on theother of said members that are connected by said narrow members arebroad.
 19. A multiple conductor electrical connector as defined in claim17 wherein said narrow members comprise knives, and electricallyconductive segments on the other of said members that are contacted bysaid knives are wires.
 20. An electrical connector comprising: firs andsecond members, each having a connecting means provided on a majorsurface thereof for engagement with one another so as to physicallyfasten said first and second members together, said connecting means foreach member comprising a structured surface including a plurality oftapered elements, said tapered elements each having a tapered sideinclined relative to a common plane in each of said members so that whenthe connecting means of said members are engaged with one another saidtapered elements of said first member intermesh with tapered elements ofsaid second member while contact surfaces of said tapered sides of saidtapered elements are engaged with one another without interlocking ofsaid tapered elements, said first and second members each comprising anelectrically insulative body and an electrically conductive segment,wherein an electrically conductive segment is provided as the contactsurface of at least one of said tapered sides of said tapered elementsof each of said members so that an electrically conductive segment ofsaid first member engages with an electrically conductive segment ofsaid second member when said first and second members are fastenedtogether to provide an electrical connection, and the contact surfacesof at least one of said tapered sides of a tapered element of eachmember are free of electrically conductive segments.
 21. A multipleconductor electrical connector comprising: first and second members,each having a connecting means for engagement with one another so as tophysically fasten said first and second members together, saidconnecting means for each member comprising a tapered side inclinedrelative to a common plane in each of said members so that when theconnecting means of said members are engaged with one another contactsurfaces of said tapered sides are engaged with one another withoutinterlocking of said tapered sides of said members, said first andsecond members each comprising an electrically insulative body and aplurality of electrically conductive segments, wherein a plurality ofelectrically conductive segments which are insulated from one anotherare provided as the contact surface of a tapered side of each of saidmembers so that electrically conductive segments of said first memberengage with electrically conductive segments of said second member whensaid first and second members are fastened together to provide aplurality of electrical connections, and the engagement betweenelectrically conductive segments at each electrical connection alsoprovides the only physical fastening that is needed in order to provideeach electrical connection with sufficient force t ensure suchelectrical connection.